Stalk Roll

ABSTRACT

One embodiment of a stalk roll to be mounted upon a stalk roll drive shaft of a corn harvesting header comprises a cylindrical shell with a recess in the main cylinder, wherein reduced flutes are not present in the recess, but full flutes are present therein. This embodiment includes a stalk slot having a length equal to the length of the recess. Additionally, the flutes may be configured such that a stalk engagement gap is present at least once during a full revolution of two opposing stalk rolls.

CROSS REFERENCE TO RELATED APPLICATIONS

Applicant claims priority from provisional U.S. Pat. App. No. 61/423,192filed on Dec. 15, 2010, and Applicant states that the presentapplication claims priority from and is a continuation of U.S. patentapplication Ser. No. 13/327,398 filed on Dec. 15, 2011, all of whichapplications are incorporated by reference herein in their entireties.

FIELD OF THE INVENTION

The apparatus described herein is generally applicable to the field ofagricultural equipment. The embodiments shown and described herein aremore particularly for improved harvesting of corn plants.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

No federal funds were used to develop or create the disclosed invention.

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTINGCOMPACT DISK APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

Modern agriculture techniques require that during separation of a cornplant ear (or “ear”) from a stalk (or “stalk”) corn harvesting machinesoptimize the following considerations: (1) increase the rate of earseparation; (2) ensure that the corn plant is not severed from its rootsystem during harvesting; (3) increase the speed at which stalks areejected from the row unit; (4) retain minimal amounts of material otherthan ears (“MOTE”) in the heterogeneous material being delivered to theharvesting machine for threshing; and, (5) lacerate and/or penetrate theshell of the stalk to expose the internal portions for accelerateddecomposition of the stalk.

As shown in FIG. 1, modern corn headers are provided with a plurality ofrow crop dividers for retrieving, lifting, and directing the rows ofstalks toward their respective corn plant engagement chambers. The cornplant engagement chamber is defined herein as the portion of the cornhead row unit that engages the stalk and separates the ear from the cornplant. FIG. 1A shows the top view of two stalk rolls found in the priorart. Gathering chains located in the corn plant engagement chamber drawthe stalks and/or ears towards the header. Stalk rolls located beneaththe gathering chains pull the stalks rapidly downward, returning thestalk to the field. These stalk rolls are typically powered by agearbox. As the stalk rolls rotate, the flutes on the stalk rolls engageand pull the stalks downward. Two stripper plates located above thestalk rolls, with one stripper plate on either side of the corn row, arespaced wide enough to allow the stalks and leaves to pass between thembut narrow enough to retain the ears. This causes the ears to beseparated from the corn plant as the stalk is pulled down through thestripper plates. The stalk rolls continue to rotate and eject theunwanted portions of the corn plant below the corn plant engagementchamber, thereby returning the unwanted portions of the corn plant tothe field.

The performance of stalk rolls found in the prior art, as shown in FIGS.3-5, has been found to be less than optimal. Attempts at increasingstalk roll performance and increasing ear separation speed have beenmade by increasing rotational speed of the stalk rolls. These attemptshave been largely unsuccessful because stalk rolls having uniform lengthflutes rotating at high speeds simulate a solid rotating cylinder(sometimes referred to as an “egg-beater effect”), which restricts entryof the corn plant into the corn plant engagement chamber. The diameterof the simulated rotating cylinder is approximately equal to thedistance from the tip of a first flute on a given stalk roll to the tipof a second flute oriented closest to 180 degrees from the first flute(i.e., two opposed flutes on a given stalk roll). This rotating-cylindereffect prevents individual flutes from engaging the stalk and restrictscorn plants from entering the corn plant engagement chamber. Thus, stalkengagement is hindered and the corn plant hesitates and does not enterthe corn plant engagement chamber.

The prior art has attempted to increase the performance of cutting orchopping stalk rolls by simply adding more flutes to the stalk rolls. Inprior art applications, this reduces the performance of the stalk rollsbecause during rotation of the stalk rolls, a semi-continuous wall ofsteel restricts entry of the stalk into the corn plant engagementchamber, as noted above. Adding flutes decreases the likelihood of astalk entering the space between two opposing stalk rolls. That is, asmore flutes are added to the stalk roll, rotation of the stalk rollcauses the stalk roll to more closely simulate a rotating cylinder. Whenviewed along the axis of rotation of the stalk roll (the direction fromwhich the stalk rolls would approach the stalk), adding more flutesrestricts the ability of the stalks to enter the corn plant engagementchamber due to interference from the ends of the flutes.

When the gathering chain paddle passes above the stripper plates andengages a stalk that is restricted from entering the corn plantengagement chamber, the gathering chain paddle will likely break orsever the stalk prior to ear separation. Stalk severance prior to earseparation increases intake of MOTE to the harvesting machine, therebyincreasing horsepower and fuel requirements. Difficulty in stalksentering the area between to stalk rolls may also cause ear separationto take place near the opening of the row unit and allow loose ears tofall to the ground, thereby becoming irretrievable.

FIG. 3 shows prior art opposing stalk roll designs utilizing six flutesthat inter-mesh and overlap. When the flutes of this type engage thestalk, the flutes alternately apply opposing force. This knife-edgerelationship causes at least two problems. First, the corn plants areviolently tossed from side to side causing premature separation ofloosely attached ears, thereby permitting the ear to fall to the groundand become irretrievable. Second, the stalk is cut or snapped at a nodecausing long, unwanted portions of the stalk and leaves to stay attachedto the ear and remain in the row unit. This increases the amount of MOTEthe harvesting machine must process. This problem is compounded as thenumber of row units per corn head is increased.

FIG. 4 shows the prior art stalk roll design with intermeshing knifeedges as described in U.S. Pat. No. 5,404,699. As shown, the stalk rollshave six outwardly extending integral flutes. Each flute has a knifeedge that is provided with a leading surface and a trailing surface. Theleading surface of the knife edge has a ten degree forward (with respectto the rotation of the stalk roll) slope and the trailing surface has athirty degree reverse slope (with respect to the rotation of the stalkroll), both of which slopes are defined with respect to a line extendingthrough the vertex of the knife edge and the central longitudinal axisof the stalk roll. Therefore, the leading surface is steeper than thetrailing surface of each knife edge. The radially extending flutes areinterleaved with one another in an intermeshing-type arrangement. Thestalk rolls may be mounted in a cantilevered arrangement; oralternatively, in an arrangement employing nose bearings. The stalk rollcomprises a cylindrical shell formed by two semi-cylindrical pieces thatare clamped about a drive shaft. Bolts extend between the twosemi-cylindrical pieces to pull the pieces together, thereby clampingthe stalk rolls to the drive shaft.

This design, upon restricted engagement of the stalk roll with thestalk, allows the knife edges to cut stalks before pulling the stalksthrough the stripper plates to separate the ear from the stalk,effectively leaving the upper portion of the corn plant free to float inthe corn row unit as shown in FIG. 3. This requires the harvestingmachine threshing components to process a substantial portion of thestalk, which increases harvesting machine horsepower and fuelrequirements.

FIG. 5 shows the design disclosed by U.S. Pat. No. 6,216,428, which is astalk roll having bilaterally symmetric flutes with knife edges that areadjacent and overlap in the shear zone area. This design produces ashearing and cutting of the stalk using a scissor configuration producedby the leading and trailing edges of the opposing knife-edged flutes.Again, the stalks are cut off prior to ear separation. This is sometimesreferred to as a “scissor effect” and also results in the need toprocess increased amounts of MOTE.

Case IH corn heads built prior to development of U.S. Pat. No. 6,216,428used stalk rolls having four knives that are bolted to a solid shaft.Adjacent stalk rolls are registered with one another so that as thestalk rolls are rotated, the knives of the opposing stalk rolls are alsoopposing rather than intermeshing. In an opposing arrangement, theknives come into contact with opposite sides of the stalk at the samegeneral height of the stalk, thereby lacerating the stalk foraccelerated decomposition. It is important that the blades are correctlyregistered with one another, and that the blades are correctly spacedfrom one another. The stalk rolls used on Case IH corn heads requirenose bearings at the forward end (with respect to the direction oftravel of the harvesting machine during threshing) of the stalk rolls tooperate properly and may not be mounted in a cantilevered arrangement.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readilyunderstood, a more particular description of the invention brieflydescribed above will be rendered by reference to specific embodimentsillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered limited of its scope, the invention will be describedand explained with additional specificity and detail through the use ofthe accompanying drawings.

FIG. 1 is a top view of a corn head that contains a cross auger, afeeder house, a frame, and multiple row units of the prior art.

FIG. 1A is an exploded top view of a portion of one row unit of FIG. 1of the prior art showing a portion of the corn plant engagement chamber.

FIG. 2 is a cross-sectional view along the plane of A-A of one row unit,the cross auger, the cross auger trough, the feeder house, and thegathering chain from FIG. 1, as disclosed in the prior art.

FIG. 3 is a cross-sectional view of a portion of the corn head shown inFIG. 1 along the plane F highlighting the stalk rolls and stripperplates of one row unit of the prior art engaged with and shearing a cornplant.

FIG. 4 is an end view of a pair of cutting-type stalk rolls as disclosedin the prior art.

FIG. 5 is an end view of a pair of shearing-type stalk rolls asdisclosed in the prior art.

FIG. 6 is a top view of a pair of opposing stalk rolls incorporatingcertain aspects of the present disclosure.

FIG. 7 is a perspective view of a pair opposing of stalk rollsincorporating certain aspects of the present disclosure, wherein thenose cones have been removed for clarity.

FIG. 8 is an exploded view of a pair of stalk rolls shown in FIGS. 6 &7.

FIG. 9A is an end view of an opposing pair of one embodiment of thepresent art stalk rolls positioned to illustrate a first moment duringwhich the stalk engagement gap is present.

FIG. 9B is an end view of an opposing pair of one embodiment of thepresent art stalk rolls at a moment in time later than that depicted inFIG. 9A showing the stalk rolls rotated so that the stalk engagement gapis no longer present due to the first opposing flutes positioned in thestalk slot.

FIG. 9C provides an end view an opposing pair of one embodiment of thepresent art stalk rolls at a moment in time later than that depicted inFIG. 9B showing the stalk rolls rotated so that the stalk engagement gapis not present due to the second opposing flutes positioned in the stalkslot.

FIG. 9D is an end view of an opposing pair of one embodiment of thepresent art stalk rolls at a moment in time later than that depicted inFIG. 9C showing the stalk rolls rotated to a position where the stalkengagement gap is present for the second time during one revolution ofthe stalk rolls.

FIG. 9E is an end view of an opposing pair of one embodiment of thepresent art stalk rolls at a moment in time later than that depicted inFIG. 9D showing the stalk rolls rotated so that the stalk engagement gapis no longer present due to the third opposing flutes positioned in thestalk slot.

FIG. 9F is an end view of an opposing pair of one embodiment of thepresent art stalk rolls at a moment in time later than that depicted inFIG. 9E showing the stalk rolls rotated so that the stalk engagement gapis not present due to the fourth opposing flutes positioned in the stalkslot.

FIG. 10 is an end view of a second embodiment of an opposing pair of thepresent art stalk rolls having fifth and sixth flutes with a rotationalposition corresponding to the position of the stalk rolls in FIG. 9A.

FIG. 11 is an end view of an opposing pair of one embodiment of thepresent art stalk rolls illustrating flutes with knife edges.

FIG. 12 is a top view of one embodiment of a pair of stripper platesthat may be used with various embodiments of the present art stalk rollshowing various zones along the length of the stripper plates.

FIG. 13 is a top view of one embodiment of a pair of stalk rollsaccording to the present disclosure showing various zones along thelength of the stalk rolls.

FIG. 14B is a cross-sectional view of the stripper plates and stalkrolls from FIGS. 12 & 13, respectively, at line B-B.

FIG. 14C is a cross-sectional view of the stripper plates and stalkrolls from FIGS. 12 & 13, respectively, at line C-C.

FIG. 14D is a cross-sectional view of the stripper plates and stalkrolls from FIGS. 12 & 13, respectively, at line D-D.

FIG. 14E is a cross-sectional view of the stripper plates and stalkrolls from FIGS. 12 & 13, respectively, at line E-E.

FIG. 15 is a top view of another embodiment of stalk rolls incorporatingcertain aspects of the present disclosure having tapered flutes showingvarious zones along the length of the stalk rolls.

FIG. 15A is a cross-sectional view of the stalk rolls from FIG. 15 atline A-A.

FIG. 15B is a cross-sectional view of the stalk rolls from FIG. 15 atline B-B.

FIG. 15C is a cross-sectional view of the stalk rolls from FIG. 15 atline C-C.

FIG. 16 is a top view of another embodiment of stalk rolls incorporatingcertain aspects of the present disclosure having stepped flutes showingvarious zones along the length of the stalk rolls.

FIG. 16A is a cross-sectional view of the stalk rolls from FIG. 16 atline A-A.

FIG. 16B is a cross-sectional view of the stalk rolls from FIG. 16 atline B-B.

FIG. 16C is a cross-sectional view of the stalk rolls from FIG. 16 atline C-C.

FIG. 17 is a top view of another embodiment of stalk rolls incorporatingcertain aspects of the present disclosure having tapered flutes showingvarious zones along the length of the stalk rolls.

FIG. 17A is a cross-sectional view of the stalk rolls from FIG. 17 atline A-A.

FIG. 17B is a cross-sectional view of the stalk rolls from FIG. 17 atline B-B.

FIG. 18 is a cross-sectional view of FIG. 13 along line D-D with a stalkengaged with the stalk rolls.

FIG. 18A is a detailed view of the stalk after penetration of the stalkby the stalk roll.

FIG. 19A is a cross-sectional view of one embodiment of stalk rollsincorporating certain aspects of the present disclosure showing theangle of the flute edges prior to engagement with a stalk.

FIG. 19B is a cross-sectional view of one embodiment of stalk rollsincorporating certain aspects of the present disclosure showing theangle of the flute edges as they would be during engagement with astalk.

FIG. 20 is a cross-sectional view of one embodiment of a corn headincorporating certain aspects of the present disclosure.

FIG. 21A is a perspective view of a first embodiment of a stalk rollhaving a recess.

FIG. 21B is a second perspective view of the first embodiment of a stalkroll having a recess.

FIG. 21C provides a detailed view of a flute in the first embodiment ofa stalk roll having a recess.

FIG. 22A is an end view of the first embodiment of two stalk rollshaving recesses intermeshed with one another.

FIG. 22B is another end view of the first embodiment of two stalk rollshaving recesses intermeshed with one another wherein the nose cone hasbeen removed for clarity.

FIG. 23 is a cross-sectional view of a second embodiment of two stalkrolls having a recess intermeshed with one another.

DETAILED DESCRIPTION-ELEMENT LISTING ELEMENT DESCRIPTION ELEMENT #Gathering chain paddle   1 (110) Gathering chain   2 (120) Stripperplate   3 (130) Row divider   4 (100) Nose cone 5 Transport vane   6(170) Stalk slot 7 Cross auger trough   8 (200) Cross auger   9 (220)Cross auger fighting  10 (230) Feeder house 11 Stalk roll (Prior Art) 12Ear  13 (300) Outer shell of stalk  14 (321) First (right) stalk roll 15Second (left) stalk roll 16 Cylindrical shell 17 First flute 18 Secondflute 19 Third flute 20 Fourth flute 21 Knife edge 22 Leading surface 23Trailing surface 24 Stalk engagement gap 25 Fifth flute 26Semi-cylindrical shell (Upper) 27 Semi-cylindrical shell (Lower) 28Stalk roll drive shaft 29 Annular ridge 30 Short bolt hole 31 Short bolt32 Sixth flute 33 Bolt receiver 34 Long bolts 36 Long bolt hole 37Intermediate drive shaft 38 Drive shaft bolt 39 Small pin 40 Large pin41 Row unit cover 100 Ear separation chamber 140 Short flute 180 Taperedflute 181 Intermediate flute 182 Long flute 183 Stalk roll 190 (192)Underside of leaf 310 Stalk 320 Stalk outer shell 321 First grasp point322 Second grasp 323 Stalk cut point 324 Stalk piece 326 Stalk node 330Stalk roll 400 Nose cone 410 Flighting 412 Recess 420 Main cylinder 430Full flute 440 Flute edge 442 Leading surface 444 Trailing surface 445Leading wall 446 Trailing wall 447 Beveled edge 448 Flute base 449Reduced flute 450

DETAILED DESCRIPTION

Before the various embodiments of the present invention are explained indetail, it is to be understood that the invention is not limited in itsapplication to the details of construction and the arrangements ofcomponents set forth in the following description or illustrated in thedrawings. The invention is capable of other embodiments and of beingpracticed or of being carried out in various ways. Also, it is to beunderstood that phraseology and terminology used herein with referenceto device or element orientation (such as, for example, terms like“front”, “back”, “up”, “down”, “top”, “bottom”, and the like) are onlyused to simplify description of the present invention, and do not aloneindicate or imply that the device or element referred to must have aparticular orientation. In addition, terms such as “first”, “second”,and “third” are used herein and in the appended claims for purposes ofdescription and are not intended to indicate or imply relativeimportance or significance. “Stalk roll” 15, 16, 190, 192, 400 is notlimited to any specific embodiment or feature disclosed herein, but ismeant to include any present art stalk roll that is configured with oneor more inventive feature as disclosed and claimed herein.

1. First Embodiment of Stalk Rolls with a Stalk Engagement Gap

Referring now to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout the several views, thegeneral operation of corn heads having stalk rolls mounted thereon ofthe type illustrated in FIGS. 6-9 is similar to the operation of cornheads using stalk rolls 12 of the prior art (as illustrated in FIGS.1-5). As used herein, “left” and “right” are defined from theperspective of a corn plant with respect to a harvesting machine.

The power source for this corn head row unit is provided from a stalkroll drive shaft 29 through a gearbox, as described in the prior art andis well known to those skilled in the art and not pictured herein. Eachcorn head row unit on a corn header is provided with a first and secondstalk roll 15, 16 arranged parallel to one another to make an opposingpair. The first and second stalk rolls 15, 16 are provided with nosecones 5 having transport vanes 6. Immediately behind the nose cones 5are cylindrical shells 17 having a first, second, third, and fourthflute 18, 19, 20 and 21, respectively, mounted along the length of thefirst and second stalk rolls 15, 16 (as can easily be seen in FIG. 6).Each flute 18, 19, 20, 21 may further be provided with a knife edge 22,as is shown in detail in the embodiment depicted in FIG. 11. The knifeedges 22 are substantially parallel to the central longitudinal axis ofthe cylindrical shell 17. As shown in the embodiment in FIGS. 6-9, thestalk rolls 15, 16 may be mounted in the cantilevered manner forrotation by their respective stalk roll drive shafts (not shown),thereby eliminating the need for support brackets or nose bearings.

As with corn headers employing stalk rolls 12 of the prior art, thestalk rolls 15, 16 of the present disclosure pull the stalk 320 in adownward motion, causing the ears 13 to contact the stripper plates 3and separate from the stalk 320. The flutes 18, 19, 20, 21 affixed tothe stalk rolls 15, 16 may also act to lacerate or crush the stalk 320,and also facilitate ejection of the stalk 320 from the corn plantengagement chamber. Gathering chain paddles 1 affixed to gatheringchains 2 transport the loose ears 13 to the cross auger trough 8. Thecross auger 9 moves the ears 13 from the cross auger trough 8 to thefeeder house 11, which moves the ears 13 into the remainder of theharvesting machine for further processing, all of which is well known tothose skilled in the art.

In an embodiment not pictured herein, the stalk rolls 15, 16 may bemanufactured as one piece adapted for engagement upon the stalk rolldrive shaft 29. In another embodiment, the first and second stalk rolls15, 16 may be built as two continuous, integral, semi-cylindrical shellsto be bolted to a stalk roll mounting base (not shown) into which thestalk roll drive shaft 29 is inserted, as is best illustrated in FIG. 8.The cylindrical shell 17 may be comprised of two semi-cylindrical shellpieces, an upper semi-cylindrical shell 27 and a lower semi-cylindricalshell 28, that are bolted to the intermediate drive shaft 38. The longbolt holes 37 and long bolts 36 with nuts or other securing members,along with the short bolt holes 31, short bolts 32, and bolt receivers34, form a structure for mounting the cylindrical shell 17 to theintermediate drive shaft 38, which then may be mounted to the stalk rolldrive shaft 29.

FIG. 8 best illustrates the mounting structure for an embodimentemploying semi-cylindrical shells 27, 28. In one embodiment, eachsemi-cylindrical shell 27, 28 is fashioned with two inwardly extendingannular ridges 30 having short bolt holes 31. Short bolts 32 passthrough the short bolt holes 31 and engage bolt receivers 34 located onan intermediate drive shaft 38. Long bolts 36 pass through the long boltholes 37 of two corresponding upper and lower semi-cylindrical shells27, 28, and with a nut or other securing member clamp thesemi-cylindrical shells 27, 28 together around the intermediate driveshaft 38. The intermediate drive shaft 38 is clamped to the stalk rolldrive shaft 29 by drive shaft bolts 39. In addition, a small pin 40 anda large pin 41 prevent relative rotation between the intermediate driveshaft 38 and the stalk roll drive shaft (not shown in FIG. 8).

Each semi-cylindrical shell 27, 28 may be manufactured having at leasttwo integral flutes. In one embodiment, the flutes are then machined todefine the knife edge 22. Each knife edge 22 has a leading surface 23and a trailing surface 24 that form an acute angle between them ofapproximately forty degrees, as shown in the embodiment pictured in FIG.11. The leading surface is a rearward (with respect to the direction ofrotation of one of the stalk rolls 15, 16 of an opposing pair) slopingsurface, sloping approximately ten degrees from a line passing throughthe central longitudinal axis of the cylindrical shell 17 and the vertexof the knife edge 22. The trailing surface 24 is a forward (with respectto the direction of rotation of one of the stalk rolls 15, 16 of anopposing pair) sloping surface, sloping approximately thirty degreesfrom a line passing through the central longitudinal axis of thecylindrical shell 17 and the vertex of the knife edge 22. Other slopesand angles of the leading surface 23 and the trailing surface 24 may beused without departing from the spirit or scope of the stalk roll 15,16. As is well known to those skilled in the art, tungsten carbide maybe applied to the trailing surfaces 24 to make the knife edges 22self-sharpening. Although not shown, the layer of tungsten carbide isgenerally between three and twenty thousandths of an inch thick and isinduction hardened.

As illustrated in FIGS. 6-9, the flutes 18, 19, 20, 21 of the opposingfirst and second stalk rolls 15, 16 are offset to one another but notinterleaved. As those of ordinary skill in the art will appreciate,though not pictured, the stalk roll design disclosed herein may also beimplemented with a rounded flute edge or edge that does not haveknife-like characteristics. Accordingly, the scope of the stalk roll 15,16 is not limited by type of edge fashioned on the flute or the specificcross-sectional shape of the flute.

The present art alleviates the impediment to flow of stalks 320 into thecorn plant engagement chamber (which impediment is a result of theegg-beater effect, as described above) by creating at least one stalkengagement gap 25 in the stalk slot 7 per revolution of the stalk roll15, 16, which is explained in detail below. When the stalk engagementgap 25 is present, corn plant entry into the corn plant engagementchamber is not restricted.

As may be seen for the embodiment in FIGS. 9A-9F, the width of the stalkslot 7 is defined as the distance between the inner periphery of thecylindrical shells 17 of the opposing stalk rolls 15, 16, which width isdenoted “W” in FIGS. 9A-10. Other embodiments described in detail belowinclude an recess 420, which may affect the width of the stalk slot 7.The height of the stalk slot 7 is essentially infinite, though inpracticality the ground surface provides a lower limit. The stalkengagement gap 25, as shown in FIGS. 9A, 9D, and 10, is then defined asthe moment(s) during revolution of the first and second stalk rolls 15,16 in which none of the flutes 18, 19, 20, 21 of the first or secondstalk roll 15, 16 are positioned within the stalk slot 7. FIGS. 9B, 9C,9E, and 9F illustrate the stalk slot 7 after the stalk engagement gap 25is closed.

FIGS. 9A-9F provide six views of the stalk slot 7 at six differentmoments during one revolution of the stalk rolls 15, 16, with thedirection of rotation of the stalk rolls 15, 16 indicated by therespective arrows. As will be explained in detail below, the embodimentshown in FIGS. 9A-9F is configured so that the stalk engagement gap 25is present at two different moments in time during one revolution of thestalk rolls 15, 16; and as will be apparent to those skilled in the art,this is but one of many embodiments the stalk rolls 15, 16 may take.Throughout one revolution of the stalk rolls 15, 16, at any point intime, the flutes 18, 19, 20, 21 may be engaged in five different modesof action upon a stalk 320 at any point along the axial length of theflute 18, 19, 20, 21 (depending on the location and orientation of theflutes 18, 19, 20, 21 and the particular embodiment). The five modes ofaction upon the stalk 320 are: (1) unrestricted entry of the stalk 320into the corn plant engagement chamber (which occurs at the moment intime shown in FIGS. 9A and 9D, although restricted entry may occur atother moments in time); (2) flute 18, 19, 20, 21 or knife engagementwith the stalk 320 (which may occur at moments in time shown in FIGS.9B, 9C, 9E, and 9F, but may also occur at other moments in time); (3)lacerating and crushing of the stalk 320 by the flutes 18, 19, 20, 21 orknives (which may occur at the moments in time shown in FIGS. 9B, 9C,9E, and 9F, but may also occur at other moments in time); (4) earseparation and stalk 320 ejection (which may occur at moments in timeshown in FIGS. 9B, 9C, 9E, and 9F, but may also occur at other momentsin time); (5) stalk 320 release by the stalk rolls 15, 16 for lateraltravel of the stalk 320 (which most often occurs at moments in timeshown in FIGS. 9A and 9D, but may also occur at other moments in time).

FIG. 9A shows the stalk engagement gap 25, and illustrates that when thestalk engagement gap 25 appears, no flutes 18, 19, 20, 21 are located inthe stalk slot 7. When the stalk rolls 15, 16 are in this position astalk 320 (not shown) may freely enter the stalk slot 7 and the cornplant engagement chamber with no restriction. The stalk engagement gap25 also allows stalks 320 already positioned between the stalk rolls 15,16 to travel in a lateral direction to compensate for the forward motionof the harvesting machine to which the corn head is attached.

FIG. 9B shows the stalk slot 7 at a later moment in time after the stalkrolls 15, 16 have rotated from their positions shown in FIG. 9A. FIG. 9Bshows that at this point, the first flute 18 of each stalk roll 15, 16has moved into the stalk slot 7 so that there is no stalk engagement gap25, and the first flutes 18 of the respective stalk rolls 15, 16 nowengage any stalk 320 between the stalk rolls 15, 16. This engagement mayserve to lacerate or crush the stalk 320, or to pull the stalk 320downward through the corn plant engagement chamber and subsequentlyeject the stalk 320 depending on the specific embodiment.

FIG. 9C shows the stalk slot 7 at still a later moment in time whereinthe second flute 19 of each stalk roll 15, 16 has moved into the stalkslot 7 so that there is still no stalk engagement gap 25. The secondflutes 19 of each respective stalk roll 15, 16 now engage any stalk 320between the stalk rolls 15, 16. This engagement may serve to lacerate orcrush the stalk 320, or to pull the stalk 320 downward through the cornplant engagement chamber and subsequently eject the stalk 320 dependingon the specific embodiment.

FIG. 9D provides a snapshot of the stalk slot 7 at a moment in timelater than the moment depicted in FIG. 9C, and shows the stalkengagement gap 25 present for the second time during this revolution ofthe stalk rolls 15, 16. The stalk engagement gap 25 is present since noflutes 18, 19, 20, 21 are positioned within the stalk slot 7 when thestalk rolls 15, 16 are positioned as in FIG. 9D, and a stalk 320 (notshown) may again freely enter the stalk slot 7 and the corn plantengagement chamber with no restriction. Again, the stalk engagement gap25 also allows stalks 320 already positioned between the stalk rolls 15,16 to travel in a lateral direction to compensate for the forward motionof the harvesting machine to which the corn head is attached.

FIG. 9E shows the stalk slot 7 at a later moment in time from the momentshown in FIG. 9D wherein the third flute 20 of each stalk roll 15, 16has moved into the stalk slot 7 so that there is no stalk engagement gap25. At this point, the third flutes 20 of the respective stalk rolls 15,16 now engage any stalk 320 between the stalk rolls 15, 16. As withsimilar moments in time already explained, this engagement may serve tolacerate or crush the stalk 320, or to pull the stalk 320 downwardthrough the corn plant engagement chamber and subsequently eject thestalk 320 depending on the specific embodiment.

FIG. 9F shows the stalk slot 7 at still a later moment in time whereinthe fourth flute 21 of each stalk roll 15, 16 have moved into the stalkslot 7 so that there is still no stalk engagement gap 25. Here, thefourth flutes 21 of the respective stalk rolls 15, 16 engage any stalk320 between the stalk rolls 15, 16. Again, this engagement may serve tolacerate or crush the stalk 320, or to pull the stalk 320 downwardthrough the corn plant engagement chamber and subsequently eject thestalk 320 depending on the specific embodiment. As will be apparent tothose skilled in the art, the next snapshot in time of the stalk slot 7according to the pattern indicated by FIGS. 9A-9F will be identical toFIG. 9A, and would provide the last view of one full revolution of thestalk rolls 15, 16.

FIGS. 6-9 show an illustrative embodiment wherein the stalk rolls 15, 16and their respective flutes 18, 19, 20, 21 are configured so that twostalk engagement gaps 25 appear per revolution of the stalk rolls 15,16. As those of ordinary skill in the art will appreciate, the stalkrolls 15, 16 and their respective flutes 18, 19, 20, 21 may beconfigured so that nearly any number of stalk engagement gaps 25 appearper revolution of the stalk rolls 15, 16. For example, although notshown in the figures herein, one of ordinary skill in the art couldeasily add a fifth flute to the stalk rolls 15, 16 between the fourthand first flutes 18, 21 on each stalk roll 15, 16; and thereby reducethe number of stalk engagement gaps 25 per revolution of the stalk rolls15, 16 from two to one.

In the illustrative embodiment shown in FIGS. 6-9, two structuralfeatures are necessary to create two stalk engagement gaps 25 perrevolution of the stalk rolls 15, 16. First, the flutes 18, 19, 20, 21of each stalk roll 15, 16 must be positioned around the circumference ofthe stalk roll 15, 16 in a non-equidistant manner. That is, thecircumferential distance between the first flute 18 and fourth flute 21is greater than the circumferential distance between the third flute 20and fourth flute 21 on each stalk roll 15, 16. Likewise, thecircumferential distance between the second flute 19 and third flute 20is greater than the circumferential distance between the first flute 18and second flute 19 of each stalk roll 15, 16. However, this may beachieved using flutes 18, 19, 20, 21 of different lengths so as to varythe circumferential distance between terminal ends of flutes 18, 19, 20,21. Second, the first stalk roll 15 of an opposing pair is positioned onits respective stalk roll drive shaft 29 so that it is slightly advanced(with respect to rotational positions of the flutes 18, 19, 20, 21)compared to the second stalk roll 16 of the pair. During operation, thestalk rolls 15, 16 operate at the same rotational speed so that thedifference in positioning is maintained throughout operation. Becausethe stalk rolls 12 of the prior art and the flutes thereon are notconfigured to yield any stalk engagement gaps 25, they essentiallycreate a wall of rotating steel as previously described, which restrictsthe entry of the stalk 320 into stalk slot 7 and the corn plantengagement chamber.

FIG. 10 provides an end view of another embodiment of stalk rolls 15,16. In this embodiment, a fifth flute 26 is added between the firstflute 18 and second flute 19 so that the distance between the firstflute 18 and the fifth flute 26 is equal to the distance between thesecond flute 19 and the fifth flute 26. A sixth flute 33 has also beenadded between the third flute 20 and the fourth flute 21 so that thedistance between the third flute 20 and the sixth flute 33 is equal tothe distance between the fourth flute 21 and the sixth flute 33. FIG. 10depicts a moment when the stalk engagement gap 25 is present, therebyallowing stalks 320 to enter the corn plant engagement chamber. In thisembodiment, as in the embodiment shown in FIGS. 9A-9F, the stalkengagement gap 25 appears twice per revolution of the stalk rolls 15,16.

In an alternative embodiment not shown herein, additional flutes thathave a smaller axial length as compared to the axial length of flutes18, 19, 20, 21 could be placed between all or some of flutes 18, 19, 20,21. (Alternatively some of the original flutes 18, 19, 20, 21 could befashioned with a smaller axial length than the axial length of adjacentflutes 18, 19, 20, 31.) Here, the additional flutes would not extend theentire distance of the cylindrical shell 17. Instead, the additionalflutes would only extend along the cylindrical shell 17 from a pointproximal to the end of the cylindrical shell 17 closest to the crossauger 9 (which may be the same point from which the flutes 18, 19, 20,21 extend, as shown in FIG. 6) to a point distal from the cross auger 9,but not the entire length of the cylindrical shell 7 up to the interfacebetween the cylindrical shell 17 and the nose cone 5. That is, theadditional flutes would not extend radially from the cylindrical shell17 on a portion of the cylindrical shell 17 that is distal from thecross auger 9 (and also distal to the connection between the stalk rolldrive shaft 29 and the corn header). This embodiment facilitates stalkrolls 15, 16 that are configured so as to provide a stock engagement gap25 along a predetermined axial portion of the stalk rolls 15, 16 thatfirst engage the stalk 320 (i.e., a portion distal from the cross auger9) while still providing more flutes to engage the stalk 320 in the cornplant engagement chamber on a portion of the stalk rolls 15, 16 proximalto the corn header (which may assist in decomposition of the stalk 320and harvesting speed).

As is apparent from the embodiment shown in FIG. 10, the specific numberand orientation of flutes 18, 19, 20, 21, 26, 33 employed on a stalkroll 15, 16 may vary. Therefore, the precise number of flutes 18, 19,20, 21, 26, 33 employed in a particular embodiment, or the specificorientation thereof in no way limits the scope of the present stalk roll15, 16. As long as the flutes 18, 19, 20, 21, 26, 33 are oriented uponthe stalk rolls 15, 16 and the stalk rolls 15, 16 are orientated withrespect to each other such that at least one stalk engagement gap 25appears during one revolution of the stalk rolls 15, 16, the specificorientation or number of flutes 18, 19, 20, 21, 26, 33 are not limitingto the scope of the present stalk roll 15, 16. Furthermore, what isreferred to herein as a cylindrical shell 17 of the stalk rolls 15, 16need not be fashioned as a perfect cylinder; rather, it may be fashionedso that the cross-sectional area changes along the axial length (e.g.,tapered), or be fashioned with any cross-sectional shape that performsin a relatively satisfactory manner.

2. Other Embodiments of Stalk Rolls with a Stalk Engagement Gap

Another embodiment of a pair of stalk rolls 190 implementing a stalkengagement gap 25 is shown in FIGS. 13-14E. A pair of beveled stripperplates 130 is shown in FIG. 12, and lines B-B, C-C, D-D, and E-Erepresent various zones along the lengths of the stripper plates 130 andstalk rolls 190. The stalk rolls 190 and stripper plates 130 from FIGS.12 and 13 are shown in cross section at various positions along thelengths thereof in FIGS. 14B-14E. The embodiment of the stalk rolls 190and stripper plates 130 shown in FIGS. 12-14E are configured to createfour distinct (but interrelated and overlapping) zones along the lengthsthereof, each of which zone performs a separate function and purposewithin the row unit. The combination of zones, relationships, andsub-function are designed to improve the performance of the corn headand harvesting machine by allowing better material flow through the rowunit, reducing congestion and MOTE levels through the row unit,conveying systems, and the harvesting machine; thereby improvingharvesting machine speeds and efficiencies. The four (4) currentinterrelated overlapping zones are the Alignment, Entry, Ear Separation,and Post-Ear Separation Plant Ejection Zones.

A. The Alignment Zone

In the embodiment pictured in FIGS. 12-14E, the Alignment Zone isgenerally about the line B-B toward the front of the stalk rolls 190 andadjacent the nose cones 5, which is best shown in FIGS. 13 and 14B. Insome embodiments, the Alignment Zone extends along the stalk rolls 190from the front of the nose cones 5 to the line B-B. The purposes of thiszone are to align, direct, and gather the corn plant for conveyance tothe Entry and/or Ear Separation Zone with the ear 300 intact andpositioned for recovery with minimal MOTE. In the Alignment Zone of theembodiment of the stripper plate 130 shown in FIGS. 12 and 14B-14E, thestripper plates 130 are substantially flat, as best shown in FIGS. 12and 14B. This reduces the tendency of ears 300 to wedge below thestripper plates 130. The transport vanes 170 on the nose cones 4 infront of the Alignment Zone serve to guide stalks 320 into the earseparation chamber 140, which is best shown in FIG. 20. The rotatingtransport vanes 170 may be either timed or non-meshing, so as to providepositive material flow in tough, damp, or high-speed harvestingconditions. One function of the transport vanes 170 generally is tocenter the stalk 320 in the ear separation chamber 140.

The stalk rolls 190 shown in FIGS. 13-14E also incorporate a stalk slot7 in which a stalk engagement gap 25 occurs intermittently. The stalkslot 7 and stalk engagement gap 25 as defined for this embodiment ofstalk rolls 190 is the same as those defined for the embodiment of stalkrolls 15, 16 shown in FIGS. 9-10. This embodiment of stalk rolls 190facilitates a stalk engagement gap 25 that occurs along a specificlength of the stalk rolls 190. As shown in FIG. 14B, the stalkengagement gap 25 first occurs toward the front of the stalk rolls 190in the Alignment Zone and extends along the entire length thereof (whichlength is shown in FIG. 13).

This facilitates simple transport of the stalk 320 from the nose cones 5to the ear separation chamber 140 between the stalk rolls 190. The stalkengagement gap 25 in the Alignment Zone is formed by placing two shortflutes 180 separated by 180 degrees on each stalk roll 190, such thatthe short flutes 180 are arranged in a knife-to-knife configuration.Another function of the transport vanes 170 is to ensure that the stalk320 does not fall forward out of the stalk engagement gap 25.

B. The Entry Zone

In the embodiment pictured in FIGS. 12-14E, the Entry Zone is generallyabout the line C-C toward the front of the stalk rolls 190, but behindthe Alignment Zone, which is best shown in FIGS. 13 and 14C. In someembodiments, the Entry Zone extends along the stalk rolls 190 from theline C-C to the front portion of the stalk rolls 190 at the terminus ofany intermediate flutes 182, which are described in detail below. Theprimary purpose of this zone is to allow entry of the stalk 320 into theear separation chamber 140 between the stalk rolls 190. The rate atwhich stalks 320 are accepted into the row unit is a major factor indetermining harvesting speed.

As explained above, prior art teaches that to increase the rate ofentry, the rotating speed of the stalk roll 12 must be increased, whichmerely increases the egg-beater effect. If the stalk 320 is not pinchedin the Entry Zone, the stalk 320 stalls in the row unit, which stallingallows the rotating flute edges to sever the stalk 320. This stall alsocauses the stalk 320 to lean away from the row unit. Consequently, earseparation often occurs near the opening of the row unit, such thatloose ears 300 fall to the ground and become irretrievable.

A stalk engagement gap 25 is also present in the Entry Zone in thisembodiment of the stalk rolls 190, which is best shown in FIG. 14C. Theshort flutes 180 in the Alignment Zone extend into the Entry Zone, andthe stalk engagement gap 25 in the Entry Zone is formed by placing twoadditional short flutes 180 adjacent to the short flutes 180 from theAlignment Zone. As shown in FIG. 14C, the four short flutes 180 are notequally spaced about the periphery of the stalk rolls 190, but insteadare positioned in groups of two. This facilitates the stalk engagementgap 25 in the Entry Zone since adjacent short flutes 180 in each pairare close enough to each other that a stalk engagement gap 25 is presentat least once during a full revolution of the stalk rolls 190. In thisembodiment a stalk engagement gap 25 is present twice during a fullrevolution in both the Alignment Zone and Entry Zone, as is evident fromFIGS. 14B and 14C.

C. The Ear Separation Zone

In the embodiment pictured in FIGS. 12-14E, the Ear Separation Zone isgenerally about the line D-D on the front half of the stalk rolls 190,which is best shown in FIGS. 13 and 14D. In some embodiments, the EarSeparation Zone extends along the stalk rolls 190 from the terminus ofan intermediate flute 182 toward the front of the stalk rolls 190 to theterminus of a long flute 183, which is described in detail below.Generally, the Ear Separation Zone extends along a greater length of thestalk rolls 190 than does any other zone. The primary purpose of thiszone is to separate the ear 300 from the stalk 320 and prevent any ears300 from falling forward out of the row unit. In this zone, theembodiment of the stalk rolls 190 shown herein pull the stalk 320through the stripper plates 130 without prematurely severing the stalk320. The maximum vertical speed at which the stalk rolls 190 consume thestalk 320 is determined by the damaging occurring to the ear 300 at agiven speed, and will vary from one variety of corn to the next.

As best shown in FIGS. 13 and 14D, intermediate flutes 183 that extendradially further from the stalk roll 190 than short flutes 180 may bepositioned in the Ear Separation Zone. Because the intermediate flutes183 are radially longer than the short flutes 180, stalk rolls 190engage stalks 320 more securely in this zone, which is evident from FIG.14D. In the embodiment shown in FIGS. 12-14E, like the short flutes 180,the intermediate flutes 182 are not intermeshed but opposed with minimalclearance so that as a flute 180, 182 on one stalk roll 190 begins toengage the stalk 320, the opposing flute 180, 182 on the other stalkroll 190 engages the stalk 320 at a point on the horizontally oppositeside of the stalk 320. This balanced engagement action reduces lateralstalk 320 whipping, which whipping can dislodge and toss the ear 300from the stalk 320, or cause the stalk 320 to prematurely break orsever. The balanced engagement action allows the stalk rolls 190 toevenly pull the stalk 320 down so that the stripper plates 130 mayrapidly separate the ear 300 from the stalk 320 in the Ear SeparationZone.

Also apparent from FIG. 14D is the fact that the Ear Separation Zonedoes not include a stalk engagement gap 25. This is because theintermediate flutes 182 are positioned in the space between the twogroups of short flutes 180 present in the Entry Zone. Accordingly, inthe pictured embodiment a total of six flutes 180, 182 are present inthe Ear Separation Zone, and they are equally spaced about the peripheryof the stalk roll 190, such that each flute 180, 182 is separated bysixty degrees. The two short flutes 180 in each pair in the Entry Zoneare also separated by sixty degrees, and each pair of short flutes 180is separated from the other by 120 degrees. A stalk engagement gap 25 isnot required in the Ear Separation Zone because at this point the stalk320 is securely positioned between the two stalk rolls 320 and thedanger of the stalk 320 falling forward out of the ear separationchamber 140 has been alleviated. That is, the egg beater effectpreviously described has been eliminated by providing a stalk engagementgap 25 in the Alignment and Entry Zones.

D. The Post-Ear Separation Plant Ejection Zone

In the embodiment pictured in FIGS. 12-14E, the Post-Ear SeparationPlant Ejection Zone is generally about the line E-E toward the back ofthe stalk rolls 190, which is best shown in FIGS. 13 and 14E. In someembodiments, this zone extends along the stalk rolls 190 from the startof a long flute 183 to the terminus of a long flute 183 toward the backof the stalk roll 190, which is described in detail below. The primarypurpose of this zone is to rapidly eject the stalk 320 from the row unitto minimize interference between MOTE and ears 300. No specific speedratio controls the operating speed of this zone. After ear separation,increasing stalk 320 ejection speed effectively reduces MOTE enteringthe threshing (kernel separation) area of the harvesting machine,thereby increasing threshing efficiency and capacity.

As shown in FIGS. 13 and 14E, this zone may include a plurality of longflutes 183, three of which are shown on each stalk roll 190. The longflutes 183 extend radially further from the stalk roll 190 than anyother flutes 180, 182. Within this zone, the long flutes 183 may be bothmeshing and non-meshing so as to create a high-speed clean out zone. Thestalk rolls 190 may also be aerodynamically designed to create a suctioneffect so that unattached MOTE from the ear separation chamber 140 ispulled downward and returned to the field. The Post-Ear Separation PlantEjection Zone may also be configured to sever, crush, chop, or otherwisemanipulate the stalk 320 to speed decomposition thereof. The variousfunctions of this zone may be achieved through different orientationsand/or configurations of flutes 180, 182, 183 in the zone, as well asthe number of flutes 180, 182, 183 therein. Accordingly, the scope ofthe stalk rolls 190 is not limited by the number of flutes 180, 182, 183in any zone, nor it is limited by the configuration and/or orientationof flutes 180, 182, 183 in any zone.

As shown in FIGS. 12 and 14E, this zone may be configured as a clean-outzone by adding short lengths of long flutes 183 between the short and/orintermediate flutes 180, 182. Using inter-meshing long flutes 183 allowsfaster ejection of small diameter stalks 320, normally found at theupper-most portion of the corn plant. The intermeshing long flutes 183of stalk rolls 190 or 192 are aerodynamically designed and assembled tocreate a down draft through the ear separation chamber 140, whichfurther enhances removal of any MOTE.

The short flutes 180, intermediate flutes 182, and/or long flutes 183may be integrally formed with one another such that a short flute 180and/or intermediate flute 182 is formed by removing a portion of a longflute 183. As a corollary, a short flute 180 may be formed by removing aportion of an intermediate flute 182. Conversely, the various flutes180, 182, 183 may be separately formed. Additionally, short and/orintermediate flutes 180, 182 present in either the Alignment or EntryZones may extend to the Ear Separation and Post-Ear Separation PlantEjection Zones, as shown in the embodiment in FIGS. 13-14E.

The height and width of the stalk engagement gap 25 have been definedpreviously herein with respect to FIGS. 9-10. The length of the stalkengagement gap 25 may vary from one embodiment of stalk rolls 190 to thenext. For example, in the embodiment of stalk rolls 190 pictured inFIGS. 13-14E, the stalk engagement gap 25 extends from the AlignmentZone to the front of the Ear Separation Zone, which is less than halfthe overall length of the stalk rolls 190. However, in other embodimentsof the stalk rolls 190, the length of the stalk engagement gap 25 may bedifferent. Accordingly, the scope of the stalk rolls 190 as disclosedand claimed herein is in no way limited by the length of the stalkengagement gap 25.

As described and specifically claimed in other patents and patentapplications owned by Applicant, the stripper plates 130 used with anyof the stalk rolls 15, 16, 190, 400 or any other stalk rolls 130 may bebeveled along their lengths, as shown in FIGS. 12 and 14B-14E. Thestripper plates 130 as shown herein have a rounded or contoured surfaceto emulate the arched under side of the corn leaf 310 with two positiveeffects. First, this allows the corn leaf to stay attached to the stalk320, reducing the level of MOTE retained in the ear separation chamber140. Secondly, this shape also improves separation of the husk from theear 300, further reducing the level of MOTE in the ear separationchamber 140. As shown in FIGS. 14B and 14C, the stripper plates 130 aresubstantially flat in the Alignment and Entry Zones, which reduces ear300 wedging below stripper plates 130, and above the transport vanes 170of the stalk rolls 190 when ears 300 are being gathered from near groundlevel. As shown in FIGS. 14D and 14E, in the Ear Separation and Post-EarSeparation Plant Ejection Zones the stripper plates 130 are normallydirectly above the fluted portion of stalk rolls 190 and are slightlycurved down. This curve may specifically emulate the arched portion orunderside of leaf 310. This improved curved shape allows smooth flow ofunwanted portions of the corn plants to pass between stripper plates 130and exit the ear separation chamber 140 while retaining the ear 300.

As shown in FIG. 18, the embodiment shown in FIGS. 12-14E allows theflutes 180, 182, 183 and stripper plates 130 to positioned closely toone another, which reduces the amount of MOTE retained in the earseparation chamber 140 in the event that stalk 320 separation (which isdefined as a cutting of the stalk 320, or other action that causes aportion of the stalk 320 to be separated from another portion thereof)takes place before ear 300 separation.

FIGS. 16-16C show another embodiment of stalk rolls 190 featuringcertain aspects of the present disclosure. In this embodiment, the shortflutes 180 (adjacent the area bisected by line A-A and best shown inFIG. 16A) of the stalk rolls 190 are opposed with one another so thatthey meet during operation. They do not, however, ever touch duringnormal operation. The distance between the stalk rolls 190 decreasesalong their length from line A-A to line B-B as shown by FIGS. 16A-16C.Additionally, long flutes 183 are positioned on the stalk rolls 190adjacent the back thereof about line C-C. This configuration providesoptimum balanced pressure against the stalk 320 in certain conditions tofirst engage the stalk 320 and then pull it down while penetrating thestalk outer shell 321, thus avoiding stalk whip during engagement of thestalk 320.

In this embodiment of stalk rolls 190, the short and intermediate flutes180, 183 may be integrally formed with one another and distinguishedfrom one another via a stair-step configuration. The distance betweenopposing flutes 180, 182, 183 may be reduced in discrete incrementsalong the length of the stalk rolls 190, as best shown in FIG. 16. Thesestalk rolls 190 could also be configured to have a stalk engagement gap25 as previously described. Furthermore, any of the stalk rolls 15, 16,190, 400 described or pictured herein may have any number of flutes 180,181, 182, 183 extending radially any suitable distance from the stalkroll 15, 16, 190, 400, and may have a combination of tapered flutes 181and other flutes 180, 182, 183. For example, in one embodiment of astalk roll 190 not pictured herein, the Ear Separation Zone may includeflutes 180, 182, 183 having four different radial dimensions, withtapered flutes 181 interspersed there about. Accordingly, the scope ofthe stalk rolls 15, 16, 190, 400 as disclosed and claimed herein is notlimited by the number of different radial dimensions by which flutes180, 181, 182, 183 extend from the stalk rolls 190.In another embodimentof the stalk rolls 190, the distance between the flutes 180, 182, 183may be reduced discretely but there may also be a taper between thosediscrete points.

3. Tapered Stalk Rolls

A further improvement described herein compromises tapering the stalkrolls to modify the configuration of the Entry Zone to further improveperformance of the Entry Zone. The tapered stalk rolls 192 shown inFIGS. 15-15C exploit a natural attribute present in standing corn—thediameter of the stalk 320 at its base (i.e., ground level) is largerthan its diameter toward the tip or tassel. The largest gap between thetapered stalk rolls 192 is at the entry to the stalk rolls 192 near thefront; the smallest gap is at the point of exit of the stalk rolls 192near the rear. This taper in the stalk rolls 192 balances the outwardforces created by the stalk 320 against the tapered flutes 181 and theinward force of the tapered flute 181 against the stalk 320. Animbalance of the forces can create a pulsation in the stalk rolls 192during operation. This pulsation creates a moment about the gearbox thatcan produce premature failure in the gearbox or its supportingmechanisms. Tapering the stalk rolls 192 reduces the potential forpulsation while promoting entry of the stalks 320 between the stalkrolls 192 and allowing aggressive engagement between the stalk rolls 192and the stalk 320. The tapering may be achieved by changing the diameterof the stalk rolls 192 along their length or the radial distance thatthe tapered flutes 181 extend from the stalk roll 192.

The embodiment of stalk rolls 192 having tapered flutes 181 shown inFIGS. 15-15C are configured for the tapered flutes 181 in theAlignment/Entry Zone (the area about line A-A) and Ear Separation Zones(the area about line B-B) to be opposed, as clearly shown in FIGS. 15Band 15A. Conversely, the tapered flutes 181 in the Post-Ear SeparationPlant Ejection Zone (the area about line C-C) are intermeshing, as bestshown in FIG. 15C. During operation, as a stalk 320 is engaged by thestalk rolls 192, the distance between the tapered flutes 181 and theopposing stalk roll 192 is reduced, thereby increasing penetration ofthe stalk 320 by the tapered flutes 181 and exerting continuous pressureagainst the stalk 320 during engagement.

Another embodiment of stalk rolls 192 having tapered flutes 181 is shownin FIGS. 17-17B. In this embodiment, all the tapered flutes 181 areintermeshing with one another, as is clearly shown in FIGS. 17A and 17B.In this embodiment of stalk rolls 192, the various zones previouslydescribed are comingled such that clear boundaries between the zones donot exist. Instead, the transition from one zone to the next is smoothand seamless. However, any embodiment of tapered stalk rolls 192 may beconfigured with a stalk engagement gap 25 by simply removing a portionof certain tapered flutes 181.

Both the tapered stalk rolls 192 and the stalk rolls 190 shown in FIGS.13, 14, and 16 are configured to achieve variable circumferential speedsalong the length of the stalk rolls 190, 192. There are at least threecritical circumferential speed ratios related to ground speed foroptimum high efficiency harvesting. The three critical speed ratios are:(1) Harvesting machine ground speed to row unit horizontal gatheringchain speed 120 (the gathering chain 120 speed must be the same as orfaster than the ground speed); (2) Harvesting machine ground speed tothe speed at which the transport vanes 170 horizontally guide stalks 320into the ear separation chamber 140; and, (3) harvesting machine groundspeed to row unit vertical ear separation speed. The vertical earseparation speed (sometimes referred to as vertical stalk speed) must bethe same as or faster than the ground speed. However, the maximumvertical stalk speed before ear 300 separation is the highest speed atwhich the ears 300 are not damaged upon impact within the row unit. Eachof these critical speed ratios constrains the operating speed of eachzone described herein. Operating outside the critical speed ratioconstraints within each zone produces sub-optimal performance.

Optimizing all the critical speed ratios, as required by high-speed,high-yield, and/or harvesting in leaning, lodged, or broken stalk 320conditions, may require the effective circumferential speed andinteraction of the multi-length, multi-angled, multi-fluted, multi-vanedstalk rolls 15, 16, 190, 192, 400 described in each in zone to varywhile accomplishing the functions described in each zone. Applicantunderstands that the various speed ratios are interrelated and effectiverow unit designs must recognize and incorporate these varied speedratios to ensure corn plant(s) remain vertical or lean slightly towardthe corn head upon engagement. Harvesting corn plants in this mannerpromotes ear separation in the targeted Ear Separation Zone and awayfrom the front of the row unit. Targeting ear separation in this zone,and manner, reduces losses from ears 300 falling forward out of the cornhead row unit and onto the ground; thereby becoming irretrievable.

4. Recessed Stalk Rolls

Another embodiment of a stalk roll 400 having a stalk engagement gap 25is shown in FIGS. 21-22. FIGS. 21A and 21B provide correspondingperspective views of the stalk roll 400, which is designed to be one ofa pair of opposed, counter-rotating stalk rolls 400 mounted to a cornhead row unit in a manner previously described. The stalk rolls 400 areshown with nose cones 410 having flighting 412 attached thereto.Typically, the nose cone 410 is shaped substantially as a cone, as shownin the embodiments of stalk rolls 400 pictured herein. The flighting 412is configured to guide stalks 320 into the ear separation chamber 140 aspreviously described.

FIGS. 21-22 illustrate a first embodiment of a stalk roll 400 having arecess 420, as described in detail below.

Each stalk roll 400 may be formed with a main cylinder 430 having arecess 420 formed therein between the front end of the main cylinder 430and the nose cone 410 as shown in FIGS. 21A and 21B. The recess 420 mayextend along the entire circumference of the stalk roll 400 (i.e., anannular recess 420). The recess 420 may be formed in the nose cone 410,or it may be formed as a separate cylinder that is later affixed to boththe main cylinder 430 and the nose cone 410. The diameter of the recess420 is less than the diameter of either the main cylinder 430 or therearward end of the nose cone 410, which is apparent from FIGS. 21A and21B. The length of the recess 420 may vary from one embodiment of thestalk roll 400 to the next, but it is contemplated that for mostembodiments the length of the recess 420 will be from 1.5 to 6 inches inlength. Additionally, for certain embodiments it is contemplated thatthe diameter of the recess 420 will vary along its length. Accordingly,the specific dimensions of the recess 420 are in no way limiting.

The embodiment of the stalk rolls 400 shown in FIGS. 21-22 include atotal of ten flutes 440, 450, wherein six of those are full flutes 440and four of those are reduced flutes 450. However, other embodiments ofthe stalk rolls 400 may have other numbers of full flutes 440 and/orreduced flutes 450 to achieve a different number of total flutes 440,450 and/or ratio of full flutes 440 to reduced flutes 450. Additionally,the reduced flutes 450 need not be the same length. The flutes 440, 450extend in a radial direction from the main cylinder 430 and/or recess420. The flutes 440, 450 in the embodiment shown in FIGS. 21-22 aresubstantially parallel to the longitudinal axis of the stalk roll 400and substantially perpendicular to a line tangent to the main cylinder430 at the flute base 449.

In a second embodiment of the stalk roll the flutes 440, 450 areoriented differently with respect to lines that are tangent to the maincylinder 430 at the flute base 449. For example, FIG. 23 provides an endview of two stalk rolls 400 intermeshed with one another wherein theflutes 440, 450 are angled forward with respect to the direction ofrotation of the stalk rolls 400.

Accordingly, the angle of the flutes 440, 450 with respect to lines thatare tangent to the main cylinder 430 at the flute base 449 in no waylimits the scope of the stalk rolls 400 as disclosed and claimed herein.

In the first embodiment of the stalk roll 400, the full flutes 440extend from the rearward end of the main cylinder 430 through the recess420 and to the rearward end of the nose cone 410, as shown in FIGS. 21Aand 21B. The reduced flutes 450 may extend from the rearward end of themain cylinder 430 to the rearward end of the recess 420. In the firstembodiment of the stalk roll 400, the reduced flutes 450 are oriented intwo pairs on opposite sides of the stalk roll 400 and the full flutes440 are arranged in groups of three on opposite sides of the stalk roll400. The circumferential distance between the flutes 440, 450 may beequal, and in the first embodiment the flutes 440, 450 are positioned atthirty six degrees from each adjacent flute 440, 450.

A detailed view of the flutes 440, 450 is shown in FIG. 21C. As shown,each flute 440, 450 includes a flute edge 442 at the vertex of a leadingsurface 444 and a trailing surface 445. The leading and trailingsurfaces 444, 445 may be connected to the main cylinder 430 and/orrecess 420 (depending on whether it is a full flute 440 or reduced flute450) with a flute base 449. The flute base 449 may have a leading wall446 adjacent the leading surface 444 and a trailing wall 447 adjacentthe trailing surface 445. In the first embodiment of the stalk roll 400,a pair of stalk rolls 400 is mounted such that stalk roll 400 rotatestoward the leading surface 444 and leading wall 446, as shown by thearrows in FIG. 22.

Each flute 440, 450 may be formed with a beveled edge 448 on the frontaxial surface thereof. In certain conditions, a beveled edge 448provides easier entry for a stalk 320 into the corn plant engagementchamber. In the embodiment shown in FIGS. 21-22, the beveled edge 448 isangled at 30 degrees with respect to the vertical. However, in otherembodiments the beveled edge 448 may be differently configured withoutlimitation.

In the first embodiment of the stalk roll 400 the trailing wall 447 andtrailing surface 445 are integral and linear, but may have otherconfigurations in other embodiments of the stalk roll 400.

In the first embodiment the leading surface 444 is angled at thirtydegrees with respect to the leading wall 446, which also creates anangle of thirty degrees between the leading surface 444 and trailingsurface 445 (and trailing wall 447 in the first embodiment). Throughtesting, Applicant has found that this orientation allows the flutes440, 452 to effectively secure the stalk 320 during ear 321 removal andsubsequently process the stalk 320 for accelerated decomposition.Additionally, this orientation allows the stalk rolls 400 to properlyrelease the stalk 320 after the ear 321 has been removed so that thestalk 320 does not wrap around the stalk roll 400. Other orientationsand/or configurations of leading surfaces 444, trailing surfaces 445,leading walls 446, trailing walls 447, and/or flute bases 449 may beused in other embodiments of the stalk roll 400 without limitation.

The embodiment shown in FIG. 23 includes leading and trailing surfaces444, 445 that are substantially parallel to one another and create aflute edge 442 that is substantially flat, which may be optimal inconditions in which it is desired that the stalk 320 be pulverizedrather than cut/lacerated. The angle between the leading and trailingsurfaces 444, 445 and the flute edge 442 in the embodiment in FIG. 23may be different than shown herein without limitation. The optimalconfiguration will vary at least based on the threshing conditions andplant variety. In the pictured embodiment, the flute edge 442 isperpendicular with respect to both the leading and trailing edges 444,445 so that the stalk rolls 400 properly release the stalk 320 afterprocessing. However, other configurations will be preferred for otheroperating conditions.

FIG. 22 shows an end view of two cooperating stalk rolls 400 configuredaccording to the first embodiment. The stalk rolls 400 in this figureare shown substantially as they would appear when mounted on a corn headrow unit. As shown, the stalk rolls 400 are mounted such that one pairof reduced flutes 450 on opposing stalk rolls 400 are adjacent oneanother twice during a full revolution of the stalk rolls 400. Thiscreates two stalk engagement gaps 25 per revolution that extend thelength of the recess 420. That is, the length of the stalk engagementgap 25 in the first embodiment of the stalk rolls 400 is equal to thedifference in the length between the full flutes 440 and reduced flutes450, which is also equal to the length of the recess 420. In the firstembodiment of the stalk roll 400 having a recess 420, the width of thestalk slot 7 is defined by the distance between the inner peripheries ofthe main cylinders 430 of the opposing stalk rolls 400. The recess 420increases the effective width of the stalk engagement gap 25 by twotimes the difference in diameter between the main cylinder 430 and therecess 420. Furthermore, the recess 420 facilitates the positioning of astalk 320 between the flute edge 442 of a full flute 440 and the recess420 when the stalk engagement gap 25 is not present in the stalk slot 7.This ensures that stalks 320 will move rearward along the length of thestalk rolls 400 during harvesting rather than stalling at the front ofthe stalk rolls 400 or being pushed forward to the nose cone 410. Inembodiments of the stalk roll 400 in which the depth of the recess 420is not constant along its length, the width of the stalk slot 7 is alsonot constant.

The embodiment of stalk rolls 400 shown in FIGS. 21-22 effectivelyremove ears 300 from a stalk 320 and also cut the stalk 320 uponejection from the stalk rolls 400. This is achieved through thesimultaneous grasp and control of the stalk 320 by a first pair offlutes 440, 450 while a second flute 440, 450 below the first pair cutsthe stalk 320. This situation is shown schematically in FIG. 22B. Thefirst pair of flutes 440, 450 secure the stalk 320 by engaging at itfirst and second grasp points 322, 323. This grasp and control of thestalk 320 allows another flute 440, 450 positioned below but adjacentthe second grasp point 323 to produce a stalk cut point 324. Thisfunctionality requires a plurality of flutes 440, 450 spaced less thansixty degrees from adjacent flutes 440, 450. That is, at least sevenflutes 440, 450 are required, and the embodiment pictured herein employsten flutes 440, 450.

Applicant expected stalk rolls 400 as shown in FIGS. 21-22 to increasethe amount of MOTE produced during harvesting compared tootherwise-identical six-flute stalk rolls. However, field testing showedthat the ten-flute stalk rolls 400 actually produced less MOTE whilesimultaneously more effectively mutilating the stalk 320 than did thesix-flute stalk rolls. Moreover, the ten-flute stalk rolls 400 operatedconsistently in multiple conditions, including high moisture (e.g.,early morning or late evening harvesting), low moisture, and variousvarieties of corn plants.

The cutting function at the stalk cut point 324 is enhanced by thesecure engagement of the stalk 320 at the first and second grasp points322, 323 and the forward slope of the leading surface 444. Instead ofslipping past the flute edge 442 at the stalk cut point 324, the stalk320 is secured by the first and second grasp points 322, 323 so that theflute edge 442 at the stalk cut point 324 can fully penetrate the stalk320. This allows the stalk rolls 400 to eject a plurality of stalkpieces 326 that resemble confetti.

Other embodiments of stalk rolls 400 incorporating a recess 420 may haveadditional or fewer flutes 440, 450 extending other distances along thelength of the stalk roll 400. Additionally, any considerations, designs,and/or orientations previously discussed for other stalk rolls 15, 16,190, 192 may be incorporated with stalk rolls 400 having a recess 420.For example, intermediate flutes 182, tapered flutes 181, and/or longflutes 183 may be positioned on the stalk roll 400 at various positionsthereof. Additionally, the considerations of the various zones describedin detail above may be incorporated into the design of the stalk rolls400.

5. Other Row Unit Considerations

As shown in the embodiment of a corn head row unit in FIG. 20 the stalks320 are lifted and guided toward the row unit by dividers 100. Gatheringchain 120 may be formed with enlarged gathering chain paddles 110, whichhelp to direct the stalks 320 and/or ears 300 toward the ear separationchamber 140. The stalks 320 may be further centered into the earseparation chamber 140 by improved stripper plates 130 described indetail above. Enlarged gathering chain paddles 110 have an increasedangle relative to the gathering chain 120, which allow the gatheringchain paddles 110 to engagement a larger number of stalks 320 and/orcorn plants, especially when harvesting leaning and/or lodged corn.

Stalks 320 are gathered and further propelled rearwardly by means of theforce imparted by transport vanes 170 on the nose cones 5, which areoppositely wound and strategically timed to be horizontally opposite.The transport vanes 170 positively direct and lock the stalk 320 intothe Alignment and Entry Zones, both of which may be configured with astalk engagement gap 25. Alternatively, the stalk engagement gap 25 maybe replaced and/or supplemented with stalk rolls 190 having taperedflutes 181 as shown in FIGS. 15-15C and 17-17B. The strategic lateralspeed imparted to the stalk 320 by rotating transport vanes 170 isdetermined by the angle of the transport vanes 170. This lateral speedmay be equal to or faster than the lateral speed imparted to the stalk320 by gathering chain paddles 110.

In the embodiment of a row unit shown in FIG. 20, the reduced number ofenlarged gathering chain paddles 110 increases the conveying capacity ofthe row unit in the ear separation chamber 140 to carry separated ears300 rearward. This improved capacity increases the conveying efficiencyof the gathering chain paddles 110 to the cross auger trough 200, whichcontains auger 220 and flighting 230 for conveying ears 300 to thefeeder house area.

FIGS. 18 and 18A show how the tapered flute-to-flute design stalk rolls192 may work in certain conditions. As the stalk rolls 192 rotate, thesharpened edges of the flutes 181 penetrate the stalk outer shell 321.The penetration of the tapered flutes 181 combined with the rotation ofthe stalk rolls 192 may simultaneously pull and lacerate the stalk 320.Because the entire row unit is moving forward during operation, thetapered flutes 181 penetrate deeper and deeper into the stalk 320 as itis pulled down into the row unit. The difference in height between thetapered flutes 181 and the stalk roll 192 results in a continuouscompressing/decompressing action against the stalk 320, which may crimpthe stalk 320.

FIGS. 19A and B illustrate the non-meshing stalk rolls 190 as theyrotate during operation. In FIG. 18A, flutes 180 are marked at the topof the rotation prior to contact with the stalk 320. As the stalk roll190 rotates, the edge of the flutes 180 will engage and begin to pinchthe stalk 320. In FIG. 19B, flutes 180 have been rotated ninety degrees.The opposing flutes 180 are directly opposite each other. The pressureexerted by flutes 180 on the stalk 320 has lead to penetration of thestalk 320. The rotation of the stalk roll 190 has pulled the stalk 320down into the corn row unit. Penetration by the flutes 180 is at maximumdepth in FIG. 18B. Opposing flutes 180 do not touch each other duringthe cycle to avoid cutting through the stalk 320 in this embodiment. Theangle of the knife edges of the flutes 180 have a predetermined slope,as described. The angle of the slopes are forward with respect to thedirection of rotation of the stalk rolls 190.

Any of the stalk rolls 15, 16, 190, 192, 400 may be mounted either in acantilevered or non-cantilevered manner, with or without nose bearings.Additionally, any of the stalk rolls 15, 16, 190, 192, 400 may beoriented in opposing, knife-to-knife configurations or intermeshedand/or interleaved configurations. As previously mentioned, non-meshingand horizontally opposite configured flutes 180, 181, 182, 183 cause theflute edges to pinch the stalk 320 simultaneously as they rotate, thusproviding that the resultant equal forces are applied to both sides ofthe engaged stalk 320 so as to eliminate corn plant whip. This keeps thestalk 320 perpendicular and reduces any whipping action that prematurelydislodges ears 300 from the stalk 320 or snaps the stalk 320 at thestalk node 330. The remaining flutes 180, 181, 182, 183 of stalk roll190 may then further pinch the stalk 320 pulling it down and rearward sothat the ears 300 are removed from the stalks 320 as they come intocontact with the desired Ear Separation Zone of stripper plates 130.

In any of the embodiments of stalk rolls 15, 16, 190, 192, 400 thevarious flutes 18, 19, 20, 21, 26, 33, 180, 181, 182, 183, 440, 450 maybe self sharpening, or may have a work hardened knife/flute edge 22,442. Furthermore, any of the knife/flute edges 22, 442 disclosed hereinmay be coated with various materials, such as chrome, tungsten carbide,or any other materials that is suitable for the specific application.

The stalk rolls 15, 16, 190, 192, 400 and various elements thereof maybe constructed of any suitable material known to those skilled in theart or suitable for a specific application. In the embodiment aspictured herein, it is contemplated that most elements will beconstructed of metal or metallic alloys, polymers, or combinationsthereof. However, other suitable materials may be used.

It should be noted that the stalk rolls 15, 16, 190, 192, 400; flutes18, 19, 20, 21, 26, 33, 180, 181, 182, 183, 440, 450; stripper plates 3,130; gathering chain paddles 1, 110; nose cones 5, 410; row dividers 4,100 and any other element and/or feature described herein are notlimited to the specific embodiments pictured and described herein, butis intended to apply to all similar apparatuses and methods forproviding the various benefits of those elements, which benefits includebut are not limited to increasing the harvesting quality and/or speed ofa harvesting machine. Modifications and alterations from the describedembodiments will occur to those skilled in the art without departurefrom the spirit and scope of the stalk rolls 15, 16, 190, 192, 400.

Furthermore, variations and modifications of the foregoing are withinthe scope of the stalk rolls 15, 16, 190, 192, 400. It is understoodthat the stalk rolls 15, 16, 190, 192, 400 as disclosed and definedherein extends to all alternative combinations of one or more of theindividual features mentioned or evident from the text and/or drawings.All of these different combinations constitute various alternativeaspects of the stalk rolls 15, 16, 190, 192, 400. The embodimentsdescribed herein explain the best modes known for practicing the stalkrolls 15, 16, 190, 192, 400 and will enable others skilled in the art toutilize the same. The claims are to be construed to include alternativeembodiments to the extent permitted by the prior art.

Having described the preferred embodiment, other features, advantages,and/or efficiencies of the stalk rolls 15, 16, 190, 192, 400 willundoubtedly occur to those versed in the art, as will numerousmodifications and alterations of the disclosed embodiments and methods,all of which may be achieved without departing from the spirit and scopeof the stalk rolls 15, 16, 190, 192, 400.

1) A flute for a stalk roll, said flute comprising: a) a leadingsurface; b) a trailing surface angled with respect to said leadingsurface, wherein an angle between said trailing surface and said leadingsurface is less than sixty degrees; and, c) a flute edge defined by saidleading surface and said trailing surface, wherein said flute edgeresides in a radial plane passing through the longitudinal axis of saidstalk roll. 2) The flute according to claim 1 wherein said flute isfurther defined as being positioned on a main cylinder of said stalkroll. 3) The flute according to claim 2 wherein said stalk roll furthercomprises a plurality of flutes positioned on said main cylinder. 4) Theflute according to claim 1 wherein said flute and said stalk roll arefurther defined such that said flute extends along an entire length of amain cylinder of said stalk roll. 5) The flute according to claim 1wherein said flute and said stalk roll are further defined such thatsaid flute does not extend along an entire length of a main cylinder ofsaid stalk roll. 6) A flute for a stalk roll, said flute comprising: a)a leading surface; b) a trailing surface angled with respect to saidleading surface, wherein said trailing surface resides in a radial planepassing through the longitudinal axis of said stalk roll, and whereinthe angle between said trailing surface and said leading surface is lessthan sixty degrees; and, c) a flute edge defined by said leading surfaceand said trailing surface. 7) The flute according to claim 6 whereinsaid flute is further defined as being positioned on a main cylinder ofsaid stalk roll. 8) The flute according to claim 7 wherein said stalkroll further comprises a plurality of flutes positioned on said maincylinder. 9) The flute according to claim 6 wherein said flute and saidstalk roll are further defined such that said flute extends along anentire length of a main cylinder of said stalk roll. 10) The fluteaccording to claim 6 wherein said flute and said stalk roll are furtherdefined such that said flute does not extend along an entire length of amain cylinder of said stalk roll. 11) A method of processing a stalk,said method comprising the steps of: a) positioning said stalk betweenfirst and second stalk rolls, wherein both said first and second stalkrolls are configured with at least seven flutes each thereon extendingradially from said first and second stalk rolls; b) grasping said stalkby engaging said stalk between a first flute affixed to said first stalkroll and a main cylinder on said second stalk roll at a first grasppoint; c) controlling said stalk by engaging said stalk between a firstflute affixed to said second stalk roll and a main cylinder on saidfirst stalk roll at a second grasp point; and, d) cutting said stalk byengaging said stalk between a second flute affixed to said first stalkroll and said main cylinder on said second stalk roll at a stalk cutpoint. 12) The method according to claim 11 wherein said main cylinderof both said first and second stalk rolls is further defined asincluding a recess formed therein, and wherein said recess is positionedtoward the front of said first and second stalk rolls. 13) The methodaccording to claim 11 wherein said first flute affixed to said firststalk roll is further defined as comprising: a) a leading surface; b) atrailing surface angled with respect to said leading surface, wherein anangle between said trailing surface and said leading surface is lessthan sixty degrees; and, c) a flute edge defined by said leading surfaceand said trailing surface, wherein said flute edge resides in a radialplane passing through the longitudinal axis of said stalk roll. 14) Themethod according to claim 11 wherein said first flute affixed to saidfirst stalk roll is further defined as comprising: a) a leading surface;b) a trailing surface angled with respect to said leading surface,wherein said trailing surface resides in a radial plane passing throughthe longitudinal axis of said stalk roll, and wherein the angle betweensaid trailing surface and said leading surface is less than sixtydegrees; and, c) a flute edge defined by said leading surface and saidtrailing surface. 15) The method according to claim 13 wherein saidfirst flute affixed to said first stalk roll is further defined ascomprising: a) a leading surface; b) a trailing surface angled withrespect to said leading surface, wherein an angle between said trailingsurface and said leading surface is less than sixty degrees; and, c) aflute edge defined by said leading surface and said trailing surface,wherein said flute edge resides in a radial plane passing through thelongitudinal axis of said stalk roll. 16) The method according to claim14 wherein said first flute affixed to said first stalk roll is furtherdefined as comprising: a) a leading surface; b) a trailing surfaceangled with respect to said leading surface, wherein said trailingsurface resides in a radial plane passing through the longitudinal axisof said stalk roll, and wherein the angle between said trailing surfaceand said leading surface is less than sixty degrees; and, c) a fluteedge defined by said leading surface and said trailing surface.